Methods for designing a bio-climatically adapted zero-energy prefabricated modular building

ABSTRACT

Methods for designing a bio-climatically adapted affordable Zero-Energy prefabricated modular building such as for housing, in which a Layered disposition of Envelope elements—including Structural Insulated Panels—in the wall, floor and roof sections, provide a highly energy-efficient Building Envelope, which together with a modular building Support Structure including Aeriated Frames, and an adequately sized renewable energy power generator system, inexpensively achieves the energetic independence of the building. In these methods, different possible configurations of the relevant elements of the Building Envelope, the building structure and the renewable power generator system are evaluated, discarding those configurations which don&#39;t meet the defined acceptable criteria for energy-efficiency, thermal isolation and water condensation risks. The building has a low environmental impact thanks to reduced greenhouse emissions during its construction and its useful life.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.16/401,320, filed May 2, 2019, which is incorporated by reference hereinin its entirety.

TECHNICAL FIELD

The present invention relates generally to the field of construction ofenergy-efficient buildings and methods of constructing such buildings.More specifically, the present invention relates to a bio-climaticallyadapted Multi-Layered Building Envelope therefor.

BACKGROUND OF THE INVENTION

Since the moment humanity became aware of the irreversible negativeimpact that the unrestricted consumption of fossil fuels and othernonrenewable energy sources in the construction industry was causing onour planet, the need for developing environmentally sensitive housingand commercial buildings was born.

At the global level, we are facing the so-called World Energy Trilemma,characterized by the increasing difficulty of balancing the concepts ofEconomy, Energy, and Environment for a given society. On one hand, wedemand more and more electric power, to the point one could say that wehave become “energyvorous”, demand which in the near future is onlyexpected to keep growing. On the other hand, the production,transportation, transformation and distribution of energy in its bestform for human use (electrical power) is very expensive, and at the sametime it usually produces a large impact on the environment to which itpertains (from the use of fossil energy—thermal power stations, combinedcycle, etc., that prevail today, to the generation of majorinfrastructure projects for power generation, which impact is notnegligible: hydroelectric dams, nuclear power plants and their waste,etc.).

In the United States, buildings are the biggest primary energyconsumers, being responsible for more than 40% of the total fossilenergy consumed by the nation. The residential and commercial sector isalso responsible for almost 35% of the nation's total greenhouse gasemissions. In addition, the substantial amount of natural resourcesconsumed, and the copious amounts of waste generated by the traditionalprocesses of building and demolishing housing and other structures,evince the desirability of creating environmentally sensitive buildings,including for housing.

These facts highlight the relevance of reducing both building energy useand building greenhouse gas emissions as a key to balancing the EnergyTrilemma. For this reason, the development of environmentally sensitivebuildings has become a trend in the United States and in the world, withparticular growth in the last decade.

The challenge of reducing the energy consumption of a building structureresides both in the sustainable generation of the energy it consumes andin the efficiency with which it utilizes such energy. Therefore,energetic independence is closely tied to the energy-efficiency of theBuilding Envelope, since the energy requirement for heating and/orcooling to keep the interior of the house at a comfortable temperaturecan be significant, globally accounting for over 35% of all energyconsumed in buildings and rising to over 60% in cold climates.

As with every new challenge technology faces, the earlier attempts ofdeveloping energetically independent buildings either failed to achievethe desired degree of energy-efficiency or did it at a cost which madethem absurdly unaffordable for a regular buyer. In 1996, the “PassivhousInstitute” was founded in Germany to establish new standards forbuildings pursuing a higher degree of energetic independence, but thesehouses still had a relatively inefficient performance and a very highcost, besides maintaining a substantial degree of greenhouse gasemissions during its construction and its useful-life. More recently,evolving from the Passivhous, the concept of “Zero-Energy homes” wasborn.

Zero-Energy homes combine advanced design and superior building systemswith energy-efficiency and on-site solar panels to produce as muchrenewable energy as they consume over the course of a year, leaving thedwellers with a zero-dollar electricity bill, and a Zero-Emissions home.The main advantage of Zero-Energy homes for the home owner is the lowcost of utilities, while at a national level it has the great advantageof a much lower environmental impact. Additionally, when implemented atthe community level, Zero-Energy homes improve energy security andresilience against power outages and natural disasters.

However, nowadays, the initial investment required to build aZero-Energy home is high. For the regular consumer, the desire ofacquiring sustainable housing (and ideally, a Zero-Energy home) iscountered by the much more pressing need of getting affordable housing.Today, the high costs of sustainable buildings make owning a housedesigned with an environmentally sustainable concept, and particularlyone that meets the ambitious standards of being a Zero-Energy home, aluxury that only a few can afford.

Thus, the paramount importance of developing much more affordableZero-Energy housing and other buildings such as commercial buildingsbecomes each day more pressing.

The goal of obtaining commercially viable Zero-Energy buildings is ofsuch an importance that major regions of the world are developingpolicies to move toward them. The ASHRAE Vision 2020 report sets outrequirements for enabling them by 2030. Numerous incentive policies,such as investment subsidies, feed-in tariff, net-metering schemes,etc., have been applied to promote the construction of Zero-Energy homesand buildings. Such programs have met with limited success so far forseveral reasons, one of them being the inherent difficulty of achievinga Building Envelope which is both energy-efficient and cost-efficient.As a result of this difficulty, only a handful of buildings thatactually meet the Zero-Energy standard exist in the world, and none ofthem was built in a carbon-neutral, affordable manner.

Prefabricated homes are generally a good way of achieving affordablehousing and reducing the use of natural resources and the greenhouse gasemissions during the construction. However, the current state of the artof prefabricated homes does not provide any options able of achievingthe Zero-Energy goal.

For those reasons, we believe that the disclosed invention will providesubstantial advancement to the field and become a valuable tool forhousing developers, manufacturers and builders, in the quest forobtaining affordable Zero-Energy homes and buildings.

SUMMARY OF THE INVENTION

An affordable Zero-Energy prefabricated modular building such as forresidential housing, commercial or industrial use—among otherpurposes—is achieved by applying some or all of the following aspects:

-   -   (a) Modular construction, in which relocatable Building Modules        are pre-manufactured and then transported to the final location        of the building, where they can be arranged and connected to        adjacent Building Modules in different configurations to provide        a building in accordance to multiple possible models of        different floor plans. These Modules include a relocatable        load-bearing Support Structure which, in the preferred        embodiment, is made of hot rolled steel members. This structure        includes a plurality of Aeriated Frames, which have the dual        purpose of providing structural stability to the building and of        providing support for the Inner and Outer portions of the        Building Envelope, defining air chambers between said Inner and        Outer portions, the thicknesses of these air chambers being        relevant for the application of the Calculation Methods included        in this disclosure, which is why the structure needs to be        designed from the beginning with the Zero-Energy goal in mind.        Means for connecting adjacent Building Modules, a foundation        providing structural support to said Building Modules and means        for attaching said Building Modules to said foundation are also        provided.    -   (b) Sustainable generation in situ, over a year, of the totality        of the electric power that the building is projected to consume        over that same year. This projection may be obtained based on        the estimated hours of daily operation of each device, in such a        way that the totality of the electricity needs for household        functions (in the case of a residential dwelling, the        electricity needed for lighting, heating, refrigeration, sockets        for the availability of operation of home appliances: TV,        Computers, washing machines, refrigerators, etc.) are covered by        renewable energy generated in situ. This goal is achieved by        virtue of a solar power generator and/or other renewable sources        appropriately sized for that end. In some embodiments, means for        energy storage may also be provided.    -   (c) An energy-efficient Building Envelope achieved using        high-performance fenestration and a Layered disposition of        Envelope Elements in the Wall-, Roof- and Floor Sections that        constitute the building's Thermal Envelope. These Envelope        Elements are arranged in such a way that results in both the air        barrier and the thermal barrier of the building being        substantially continuous. These Envelope Elements may include        sound and temperature insulating Layers, (such as glass wool        Layers), vapor barrier Layers, a plurality of Structural        Insulated Panels—in particular, for the preferred embodiment, of        Polyurethane Sandwich Panels—a plurality of boards including        wood and/or gypsum-type boards, for flooring support, wall        coverage and/or suspended ceilings, among other uses, and, for        some embodiments, additional Aeriated Supporting-Frames with the        resulting air chambers that they define. These elements are        selected so that, and disposed in a spatial configuration so        that, the conditions set out by the applicable Calculation        Methods included in this disclosure are satisfied.    -   (d) Diminished risks of superficial and interstitial water        condensation supported by a method that compares the projected        temperature at the interior surface of each of the projected        Envelope-Layers to the dew point temperature at those surfaces        and discards those configurations in which the dew point is        higher; and    -   (e) Low environmental impact, achieved by means a choice of        materials and methods of construction that involve a lower        consumption of natural resources, combined with the ability to        generate in situ, manage and efficiently use the electric power        needed to cover the energy needs of the building, substantially        reducing the greenhouse emissions associated to fossil energy        use and thus reducing the building's carbon footprint, thanks to        the reduction of greenhouse gas emissions during the        constructive process, as well as during its assembly and        fundamentally during its useful life. This reduction in the        environmental impact of the building may also be furthered, in        some implementations, by the use of recycled materials, the        environmentally-sensitive management of waste, and the reduction        of the water footprint of the building thanks to the        incorporation of a rain water collection and storage system.

The above-mentioned aspects are bio-climatically adapted by taking intoconsideration the relevant bio-climatic conditions for a bio-climaticzone in general or for the specific projected location of the buildingin particular, as a way for improving energy-efficiency and/or reducingcosts while achieving the specified Conditions. These relevantbio-climatic conditions for the sizing of the solar power generationsystem include the maximum and minimum annual temperatures, the rangesof geographical latitude variations to be considered and the radiationlevel. For the Calculation Methods, these relevant bio-climaticconditions include the maximum and minimum annual temperatures and therelative humidity spectrum at the analyzed location. These bio-climaticconditions are the ones to be considered every time reference is made—inthis specification and in the appended claims—to the “bio-climaticconditions of the projected location of the building”, being consideredas the “projected location of the building” the geographic locationwhere a specific finalized building or group of buildings is planned tobe placed, which could range from being as specific as a town, zip-codeor latitude-longitude coordinates, to being s general as a bio-climaticzone or a whole country. In any case, the maximums, minimums andaverages of the relevant bio-climatic conditions applicable to that areaare considered for the Calculation Methods. In some embodiments, theatmospheric pressures, precipitations, wind, the peak sun hours, andother bio-climatic conditions may also be considered. These variationscreate differences in terms of energy-efficiency, determiningfundamental changes in the thermal insulation and hygrothermalconditioning of the different individual implementations of thebuilding, as well as in the processes of sustainable generation ofelectric power to be used. That is why, for different temperature ranges(maximum and minimum temperatures), different ranges of relativehumidity, different results will be obtained. For this reason, therequirements of structural insulation packages throughout the Envelopewill vary for different implementations. This bio-climatic adaptation isachieved by means of determining the most accurate parameters for therenewable energy power generation system(s) of the building and by meansof selecting the configurations of materials—with their correspondingphysical properties—, dimensions, attributes and design of the relevantelements of the Building Envelope and the Support Structure, that resultadequate according to the specified standards.

To this end, Calculation Methods are provided to define the relevantparameters for providing bio-climatic adaptation to the building. Thesemethods include the “K-Max Method” in which the heat transfer at each ofthe projected intervening Envelope-Layers is calculated and thoseconfigurations in which the internal temperature of the buildingwouldn't meet the defined acceptable standard based on the bio-climaticconditions of the projected location of the building are discarded. Thismethod is used in conjunction with the No-Condensation Method whichevaluates water condensation risks, in such a way that configurationswhich don't satisfy both the K-Max Condition established by the K-MaxMethod and the No-Condensation Condition established by theNo-Condensation Method are discarded, thus ensuring a bio-climaticallyadapted, energy-efficient Building Envelope which is at the same timefree of water condensation and its consequent humidity problems.

An Optimization Method is also disclosed, which provides the steps foroptimizing the relevant parameters in such a way as to minimize thetotal cost of the Building Envelope or the building as a whole, or tomaximize the energy-efficiency of the building and/or other parameters,based on an array of possible options of materials—with their associatedphysical properties and commercial prices—that the User(manufacturer/builder, etc.) decides to include for their considerationin the application of the method.

Implementations may further include one or more of the followingfeatures:

-   -   (a) A Home Automation System for energy control and management,        including a built-in computer program designed to provide the        user with control of the generation and consumption of energy        within the building, thus facilitating energy management. In        residential applications, this system may be implemented to        provide dwellers with an increased security in the energy        supply, as well as increased efficiency in the use of it,        hygrothermal comfort, and environmental sustainability. This may        be achieved by the implementation of user-friendly        software—optionally including a mobile application or other        means for remote management—that allows the user to control the        range of operating temperatures and lighting by premises. It        also may incorporate a sensor system for the automatic        activation and deactivation of lighting and other        energy-consuming home systems and appliances, thus reducing        vampire energy consumption.    -   (b) A solar water heater for sanitary hot water generation.    -   (c) A rainwater collection and storage system.    -   (d) LED lighting, and high-performance appliances    -   (e) In some cases, means for converting any surplus energy being        left into a form suitable for selling it back to the grid;        and/or    -   (f) A method for automatically determining the properties and        positions of the primary, secondary and tertiary framing members        of the Support Structure of one or more Modules in accordance        with these specifications, in function of the desired dimensions        for the Module and of a limited set of options for open spans,        doors and windows, with their respective quantities, positions        and sizes, in such a way that the resulting Support Structure is        structurally stable, supports the doors, windows and open spans        at the specified locations and provides Aeriated Frames having a        thickness so defined as to enable the finalized building to        satisfy the Conditions set out by the Calculation Methods        included in this disclosure.

A person of ordinary skill in the art will further be able to recognizein this specification enablement for implementing a wide array ofpractical applications of the inventive concepts here disclosed that gobeyond the specific materials, methods and designs being specificallydescribed, including but not limited to: buildings utilizing methods andmaterials like the ones mentioned above, but without necessarily beingZero-Energy, such as an energy-efficient building that doesn't need toproduce in situ all (or any) of the energy it demands, a method for theconstruction of the buildings, means to adapt the above-mentionedenergy-efficient Building Envelope for its installation at a FramedSupport Structure that can be different from the one here disclosed,alternative methods for the calculation and/or optimization of theacceptable parameters of the Intervening-Layers of an energy-efficientBuilding Envelope, the above-mentioned method for automaticallydesigning the Modules' Support Structure, a panelized version of theBuilding Envelope, and a single-Module Zero-Energy building unitaccording to the disclosed materials, designs and methods, to use forexample as an energy-independent classroom, storage unit, or animalisolation chamber, among many other possible uses.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective view of an embodiment of an AeriatedFrame in accordance with the present invention.

FIG. 2 is a schematic perspective view of an embodiment of a SupportStructure in accordance with the present invention.

FIG. 3A is a perspective view of an embodiment of a house in accordancewith the present invention, constructed from two Modules.

FIG. 3B is a floor plan view of the house of FIG. 3A.

FIG. 4A is a side sectional elevation view an embodiment of a house inaccordance with the present invention, constructed from three Modules.

FIG. 4B is a perspective view of the house of FIG. 4A.

FIG. 4C is a floor plan view representing the first floor of the houseof FIGS. 4A and 4B.

FIG. 4D is a floor plan view representing the second floor of the houseof FIGS. 4A, 4B and 4C.

FIG. 5 is a schematic representation of a configuration ofEnvelope-Layers depicting the thermal behavior of an embodiment of anEnvelope-Wall-Section, in accordance with the present invention.

FIG. 6 is a schematic representation of a configuration ofEnvelope-Layers depicting the thermal behavior of an embodiment of aslopped Envelope-Roof-Section, in accordance with the present invention.

FIG. 7 is a side sectional view of an embodiment of the union between anEnvelope-Wall-Section and an Envelope-Floor-Section, in accordance withthe present invention, also depicting an embodiment of the means forsecuring a Module to a foundation.

FIG. 8 is a side sectional view of an embodiment of the union between anEnvelope-Wall-Section and a sloped Envelope-Roof-Section, in accordancewith the present invention.

FIG. 9 is a side sectional view of an embodiment of the union between aninternal SIP wall and a Floor-Section, in accordance with the presentinvention.

FIG. 10 is a side sectional view of an embodiment of the union betweenan internal SIP wall and a structural beam, in accordance with thepresent invention.

FIG. 11 is a top sectional view of an embodiment of the union betweentwo internal SIP walls, in accordance with the present invention.

FIG. 12 is a side sectional elevation view of an embodiment of a Modulein accordance with the present invention showing a sloppedEnvelope-Roof-Section, an Envelope-Wall-Section, aNon-envelope-Wall-Section and a Non-envelope-Floor-Section.

FIG. 13 is a top sectional view of an embodiment of the longitudinalunion between two Envelope-Wall-Sections each pertaining to one of twoadjacent Modules, in accordance with the present invention.

FIG. 14 is a top sectional view of an embodiment of the union betweentwo adjacent Modules in accordance with the present invention.

FIG. 15 is a partial view showing in more detail a perpendicular unionbetween two Envelope-Wall-Sections each pertaining to one of the twoadjacent Modules of FIG. 14.

FIG. 16 is a perspective view of an embodiment of a wall panel inaccordance with the present invention.

FIG. 17 is a block diagram showing the interaction between the differentdatabases and processes used in an embodiment of the Calculation Methodsin accordance with the present invention.

FIG. 18a depicts an example of a spreadsheet used for setting up apossible structure of the Sub-table one of Table one in an illustrativeembodiment of the Calculation Methods in accordance with the presentinvention.

FIG. 18b depicts an example of a spreadsheet used for setting up apossible structure of the Sub-tables two and three of Table one in anillustrative embodiment of the Calculation Methods in accordance withthe present invention.

FIG. 19 depicts an example of a spreadsheet used for setting up apossible structure of Table two in an illustrative embodiment of theCalculation Methods in accordance with the present invention.

FIG. 20 is a flow chart showing the steps for populating Table two in anillustrative embodiment of the Calculation Methods in accordance withthe present invention.

FIG. 21 depicts an example of a spreadsheet used for setting up apossible structure of Table three in an illustrative embodiment of theCalculation Methods in accordance with the present invention.

FIG. 22 is a flow chart showing the steps for populating Table three inan illustrative embodiment of the Calculation Methods in accordance withthe present invention.

FIG. 23 depicts an example of spreadsheet used for setting up a possiblestructure of Table four in an illustrative embodiment of the CalculationMethods in accordance with the present invention.

FIG. 24 is a flow chart showing the steps for populating Table four inan illustrative embodiment of the Calculation Methods in accordance withthe present invention.

FIG. 25 is a flow chart showing the steps for calculating theNo-Condensation Condition in an illustrative embodiment of theNo-Condensation Method in accordance with the present invention.

FIG. 26 is a flow chart showing the steps for calculating the K-MaxCondition in an illustrative embodiment of the K-Max Method inaccordance with the present invention.

FIG. 27 depicts an example of a spreadsheet used for setting up apossible structure of Table five in an illustrative embodiment of theCalculation Methods in accordance with the present invention.

FIG. 28 is a flow chart showing the steps for the minimization of theK-value or the Final Cost of the Envelope in an illustrative embodimentof the Optimization Method in accordance with the present invention.

FIG. 29 depicts the formulas used in in an illustrative embodiment ofthe Calculation Methods in accordance with the present invention.

DETAILED DESCRIPTION AND BEST MODE OF IMPLEMENTATION

Disclosed is a Zero-Energy modular building such as a single-story ormulti-story home, residential building, commercial building, or otherkinds of buildings, in which the Zero-Energy goal is attained in acost-efficient manner thanks to the incorporation of Support Structureand energy-efficient Building Envelope, both being a bio-climaticallyadapted.

As used in this specification and the appended claims, the term“Zero-Energy” refers to a building that can generate in-situ, over ayear, the totality of the electric power that the building is projectedto consume over that same year. It is important to note that, as thisconcept is based on a projection, the actual level of energy consumptioncan ultimately result greater than the level estimated by theprojection, if, for example, the family living in the household has asignificantly greater level of consumption than the average useconsidered by the projection. This would not mean that the building isnot Zero-Energy, as considered in this disclosure and claims, if theprojection was made according to the following guidelines:

-   -   (a) The projected energy consumption level should be obtained by        a thorough analysis of reliable, accurate and up-to-date        statistics when available or, for example, by consulting one or        more firms or independent professionals possessing the expertise        to provide such information.    -   (b) If several professional opinions are received, the most        burdensome one should be considered.    -   (c) When the average quantity of each type of device used per        household, the average energy use for each device, and the        average hours of daily, monthly and/or yearly operation of each        device are known, the calculation should be made in such a way        that the totality of the electricity needs for household        functions (in the case of a residential dwelling, the        electricity needed for lighting, heating, refrigeration, sockets        for the availability of operation of home appliances: TV,        Computers, washing machines, refrigerators, etc.) are covered by        the renewable energy generated in situ (over a year).    -   (d) As one of the most important factors involved in the        calculation of the projected energy consumption level of a        building is associated with the energy needed to heat or cool        its various inner rooms, the bio-climatic conditions of the        projected location of the building (including the outer maximum        and minimum annual temperatures), need to be taken into account        for this calculation.    -   (e) Moreover, as the Zero-Energy modular buildings here        disclosed need to satisfy the “K-Max” and “No-Condensation”        Conditions as detailed further on in this specification, the        calculation of the energy level needed to be generated in-situ        in order to make the building Zero-Energy, needs to be made        after the total thermal conductivity of the Building Envelope        has been defined, and therefore the energy demand for heating        and cooling can be accurately predicted and considered.    -   (f) Lastly, it is important to add at least an extra 10% to the        calculated energy consumption level to cover for possible        deviations from the average.

If the calculations of the projected consumption level were made in areliable way by following the above-mentioned guidelines, the buildingwill still be considered as Zero-Energy for the purposes of thisdisclosure and claims, even if in fact, once the year passes, the actualenergy consumption surpasses the actual renewable energy generation ofthe building. For this reason, these buildings are not required to butoptionally may be connected to the grid in order to cover for anyeventual energy demand that the in-situ renewable power generation ofthe building proves unable to provide.

A home or building constructed in accordance with the design, materialsand methods here disclosed, have the added advantage of lowered GreenHouse Emissions, being susceptible of achieving, in addition to theZero-Energy goal, also a Zero-Emissions goal. In the context of thepresent specification and claims “Zero-Emissions” refers to the nullemission of Green House Gasses in accordance to the Kyoto Protocol. Theemissions considered for this assessment are those incurred during theoperation and life of the project, when the building is in its modusoperandi and with its occupants living in it or using it for its finalpurpose (commercial, residential, industrial, or otherwise), consumingenergy day to day. Useful life represents the largest portion of thetotal energy consumption of a building during its entire life cycle (65%to 70% consumption) and here is where a building in accordance with thepresent invention is able to achieve the Zero-Emissions goal. Theseemissions are calculated through the product of the projected energyconsumption level as calculated above by the corresponding emissionfactor (or coefficient) as regulated by the United States' EnergyInformation Administration (EIA).

Some general aspects of the present invention have been summarized sofar in the first part of this this detailed description and in theprevious sections of this disclosure. Hereinafter, a detaileddescription of the invention as illustrated in the drawings will beprovided. While some aspects of the invention will be described inconnection with these drawings, it is to be understood that thedisclosed embodiments are merely illustrative of the invention, whichmay be embodied in various forms. The specific materials, methods,structures and functional details disclosed herein are not to beinterpreted as limiting. Instead, the intended function of thisdisclosure is to exemplify some of the ways—including the presentlypreferred ways—in which the invention, as defined by the claims, can beenabled for a Person of Ordinary Skill in the Art. Therefore, the intentof the present disclosure is to cover all variations encompassed withinthe spirit and scope of the invention as defined by the appended claims,and any reasonable equivalents thereof.

Referring to the drawings in more detail, FIG. 1 schematicallyillustrates what is considered to be an “Aeriated Frame” in the contextof this specification and claims. Every time that the terms “AeriatedFrame” or simply “Frame” are used in this specification and in theappended claims, they refer to a rigid structure satisfying these threeconditions:

-   -   (a) It is generally planar (meaning by this that it has a        thickness substantially smaller than its length and width and        that it is susceptible of being parallelly attached,        horizontally or vertically, to a panel or board in such a way as        to support it);    -   (b) it allows the free flow of air in all three directions; and    -   (c) no more than 30% of its volume is occupied by solids.

The illustrative Frame depicted by the image is formed by an arrangementof elongated members, but this does not necessarily have to be the case.The Frame may have other shapes and be made of different materials, andit would still be an “Aeriated Frame” as long as it satisfies theabove-mentioned conditions. The figure illustrates this concept in moredetail and shows a possible configuration of an Aeriated Frame. TheAeriated Frame is intended to be a part of a “Support Structure”, as theone shown in FIG. 2. For this reason, in FIG. 1 the position of theFrame relative to the Support Structure is depicted by the projection 1,of where the columns of the Support Structure would go. In this case,the shown Frame is an example of a “Floor-Frame”, and the projectionlines 1 depict where the Wall-Frames of the Support Structure would be.This way, an Inner Face 2, facing the interior of the Support Structureand an Outer Face 3, facing the exterior of the Support Structure aredefined. These two Faces further define a thickness 4, measured fromsaid Inner Face to said Outer Face, which will at the same time definethe thickness of the air chamber that it will create between any twosurfaces coupled to its Inner and Outer Faces respectively. In thisparticular example, the Frame consists of a Primary Structure 5 (anouter rectangle crossed by two longitudinal and two transversal beams)and a Secondary Structure 6 (two secondary beams coupled to the PrimaryStructure 5). This is a very simple Frame for illustration purposes, butin the preferred embodiments most Frames would be more complex thanthis. For example, for a small Module, the main rectangle of aFloor-Frame could measure 6 m by 3.5 m and be formed by hot rolled steelbeams of 10 cm square section, and have, as in the figure, 9 internalrectangles (3×3), but, for a larger Module, the main rectangle of aFloor-Frame could measure 12 m by 5 m and contain 20 internal rectangles(5×4), using the same kind of beams. Any size within these two examplesis allowable. These sizes are not absolute maximum and minimumlimitations. Instead, the limitations are given by the legal andtechnical transportation requirements applicable to each individualproject, taking into account that the finalized Module should be:

-   -   (a) “Relocatable”, meaning, as used in this specification and        the appended claims, that the whole Module should be able to be        safely transported by ground, air, or sea to the projected        location of the building, having a structure and dimensions        suitable for its transportation by the chosen means to the final        location without damage to its components; and    -   (b) “Suitable for human habitation”, according to the applicable        regulatory Framework for building constructions at the projected        location of the building.

Thus, a reasonable height for a Wall-Frame could be for example 3.5 m.For the 12 m long Floor-Frame described above, and with this height, aWall-Frame for this Module could be crossed by 2 longitudinal beams andfour columns, defining 15 internal rectangles (5×3) but all of which donot need to be of the same size. For example, if a window is desired tobe placed in the middle strip, measuring 1.2 m of height by 1.8 m ofwidth, the crossing beams should be placed accordingly, as to allow theplacement of the window at the desired location. Additional framingmembers for supporting the window should be used in this case. ARoof-Frame for a Module will probably need more secondary beams (such aspurlins) than a Floor-Frame of the same size, while its PrimaryStructure could have fewer framing members than those of theFloor-Frame. For example, for the 6 m by 3.5 m Module described above,the Roof-Frame could be crossed only by one longitudinal beam and twotransversal beams forming 6 rectangles, and then by a plurality ofpurlins coupled to these. It is important to note that the Frames do notneed to be rectangular. Other shapes and variations are allowable aslong as they define a load-bearing Support Structure for a BuildingModule having a floor, a roof and walls.

One of the conditions that an Aeriated Frame needs to satisfy, asexplained above, is that the air flow within the Frame in all threedirections should be unrestricted. That is represented by the sets ofarrows 7, 8, and 9 of FIG. 1. The arrows 7 represent the air flow intransversal direction. The arrows 8 represent the air flow inlongitudinal direction. These arrows are curved, in contrast to theprevious ones, because in the example Frame shown the air should followa curved path to avoid the framing members and find its way to theopposite side. The arrows 9 represent the air flow in vertical direction(from the Inner Face to the Outer Face, in this case). The arrows areshown pointing one way for the clarity of the representation butactually the air should be able to freely flow back and forth in eachdirection (all ways). The Aeriated Space 10 is, then, the mostly “empty”space, with a maximum of 30% of its volume being occupied by solids,defined by the Inner Face, the Outer Face and the outer boundaries of aFrame.

FIG. 2 shows a simplified example of a Support Structure made up ofAeriated Frames, these Frames being a Roof-Frame 11, four Wall-Frames 12(in other embodiments they may be more than four), and a Floor-Frame 13.All of the Frames have an Inner Face 2, facing the interior of thestructure and an Outer Face 3, facing the exterior of the structure.These Inner Faces define a Hollow Space 15, which has a size suitablefor human habitation. The original thickness 4 of a Frame is modifiedwhen a Secondary Structure 6 is added to the Primary Structure 5, thusdefining a new thickness 17 and a new Outer Face 18. The final thicknessof the new Aeriated Space 19—that is defined after all secondary,tertiary elements, etc., are added to the Frame—is the one that willultimately define the thickness of the air chamber. This thickness 17should be equal for all the Envelope-Frames of the same Type.“Envelope-Frames”, in the context of this specification and the appendedclaims, are all the Aeriated Frames which are purposed to hold anEnvelope-Section, understanding by “Envelope-Section” those Wall-, Roof-and Floor-Sections that once the Building Modules are connected togetheras planned in the floor plan, will be adjacent to the exterior of thebuilding or to a non-climatized space. These Envelope-Sections must becladded in such a way that, in conjunction with high-performanceexterior fenestration, results in both the air barrier and the thermalbarrier of the finalized building being substantially continuous.Contrarily, those Frames which will not hold an Envelope-Section areconsidered as Non-envelope-Frames. The Envelope-Frames can be of threeTypes: Wall-Frames, Roof-Frames and Floor-Frames. This means that, forproviding a thermally homogeneous Building Envelope, the thickness 17 ofall the Envelope-Wall-Frames, across all of the Modules, should besubstantially identical to each other, the thicknesses 17 of all theEnvelope-Roof-Frames, across all of the Modules should also besubstantially identical to each other, and the thicknesses 17 all theEnvelope-Floor-Frames, across all of the Modules should be substantiallyidentical to each other too. The thicknesses of Envelope-Wall-Frames,however, may be different from those of Envelope-Roof-Frames andEnvelope-Floor-Frames, and the Envelope-Floor-Frames different from theEnvelope-Roof-Frames. Furthermore, the thicknesses of the Frames thatare not purposed to hold Envelope-Sections (Non-envelope-Frames, forexample those which will hold internal walls or internal roofs/floors inmulti-story buildings), do not need to be the same than those which willbelong to Envelope-Sections (they can be thinner, as thermal isolationis not required for internal walls, or thicker, if the separationbetween floors need additional framing for structural support). A sameFrame can be mixed, having some areas purposed to hold Envelope-Sectionsand other areas purposed to hold Non-envelope-Sections. In this case,only the areas of the Frame that are purposed to hold Envelope-Sectionsshould comply with the required thickness. The Primary Structure 5includes, in this particular example, a cuboid perimetral container 16whose edges are crossed by two longitudinal beams for every Frame andtwo additional transversal beams for the Roof-Frame and the Floor-Frame.These numbers may of course be different depending on the size anddesign on the Module. The Frames need not be rectangular, and theSupport Structure may take the form of any regular or irregularprismatic shape in addition to cuboids. Moreover, the Support Structuredoes not even need to contain elongated members, as long as the Framesare planar and Aeriated as defined above. The general cuboid designconfiguration shown by FIG. 2, and minor variations thereof, however,are preferred because of their practicality, ease, and thecost-effectiveness of their making. In FIG. 2, the cuboid perimetralcontainer 16 defines 6 Inner rectangular openings 14 (one for eachFrame).

FIG. 3A and FIG. 3B show a simple single-story two-Module home, whileFIGS. 4A, 4B, 4C and 4D show a simple two-story, three-Module home, allaccording to some possible embodiments of the present invention. Inthem, two Building Modules (20 and 21) are shown in FIGS. 3A, 3B, 4A, 4Band 4C, and a third Building Module 29 is shown in FIGS. 4A, 4B and 4D.The terms “Building Module” or simply “Module” as used in thisspecification and the appended claims, refer to a relocatableprefabricated unit formed by a load-bearing Support Structure asdescribed by this specification and the Envelope and Non-envelope-Wall-,Floor- and Roof-Sections (in some cases, including fenestration) coupledto it, and that will be transported as a whole to the building site forits final installation. A Module's Support Structure does not need to becompletely cladded before its transportation to the building site.Instead, some areas of it may be purposely left uncovered, to befinished in situ once the Modules are affixed to any adjacent Modulesand/or to the foundation. This can facilitate the unions betweenModules, as will be shown later in more detail. In FIGS. 3B, 4A, 4C and4D, the Modules 1, 2 and/or 3, are signaled by the dotted rectangles 20,21 and/or 29 respectively. These rectangles designate the two or threedistinct rectangular areas of the home, while in the perspective viewsshown in FIG. 3A and FIG. 4B, the Modules are generally depicted asbeing each one of the shown generally cuboid 3D shapes that form thehomes. The dotted surfaces 22 for all these figures designate theEnvelope-Sections of the homes. Examples of Non-envelope-Sections areshown in FIGS. 3A, 3B, 4C and 4D with number 23. In FIG. 3A a supportingstructure 26 for a solar water heater 27 can be seen. That structuredoes not need to be climatized because it is not purposed for humanhabitation. FIG. 3B, also depicts this supporting structure 26. Besides,both FIGS. 3 show some walls 23 which are Non-envelope-Sections (becausethey are not adjacent to both exterior or non-climatized areas andinterior or climatized areas), and so do FIGS. 4C and 4D. In FIGS. 3A,4A and 4B, solar panels for the solar power generation system 25 areshown. A properly sized renewable energy power generation system isessential to provide a Zero-Energy home or building. FIGS. 3A and 3Balso show a non-climatized entrance hall 28. As its walls areNon-envelope-Walls, to maintain the continuity of the air and thermalbarriers of the Envelope, the inner wall adjacent to that is anEnvelope-Wall 22 and the sliding door connecting to it, ahigh-performance door 24. Contrarily to this entrance hall, which isnon-climatized, FIGS. 4A, 4B, and 4C show a climatized entrance hall 30.In this design, the hall is thermally protected by Envelope-Sections andhigh-performance fenestration. Whenever the term “high-performance” isused in reference to windows, doors or fenestration in general in thecontext of this specification and the appended claims, said fenestrationis subject to the following requirements: U-value of no more than 0.30Btu/h·ft²·° F. for fixed fenestration, no more than 0.38 Btu/h·ft²·° F.for operable fenestration and no more than 0.77 Btu/h·ft²° F. forentrance doors, all having an Air Leakage of no more than 0.25 cf·m/ft².High-performance fenestration is shown in FIGS. 3A, 3B, 4B, 4C, and 4Dwith the reference number 24. A staircase 31 connects the first-floorand second-floor modules of FIGS. 4C and 4D.

FIG. 5 and FIG. 6 show schematic representations of the Envelope-Layersfor an embodiment of an Envelope-Wall-Section (FIG. 5) and an embodimentof a sloped Envelope-Roof-Section (FIG. 6). Basically, the“Envelope-Layers” (or, simply “Layers”) in accordance with thisinvention are all the Structural Insulated Panels, Boards,Supporting-Frames, Sheets, Insulating-Layers and any optionalAdditional-Intervening-Layers that form part of anEnvelope-Wall-Section, an Envelope-Roof-Section, or anEnvelope-Floor-Section.

The concept of layers in this specification and the appended claims, isapplied in a general way that does not imply that these layers need tobe parallel to be considered as Layers, as FIG. 6 illustrates for thecase of a sloped roof. Typically, though, Layers in many embodiments ofthe Floor and the Wall Envelope-Sections will be parallel (they maypresent many different variations, but as long as they behave as“Intervening-Layers” they are still considered Layers in the context ofthis disclosure and claims). The non-parallel Layer case will be presentin many possible embodiments of Modules having sloped roofs. Theimportance of these Layers is that they need to be applied all aroundthe Envelope-Sections of the building in a continuous fashion, in such away as to ensure, together with the high-performance fenestration, thecontinuity of the thermal barrier and the air barrier of the Envelope,and in such a way that the Calculation Methods described by thisdisclosure can be accurately applied. For example, in an embodiment inwhich a home has both a sloped Envelope-Roof-Section, and a non-slopedEnvelope-Roof-Section, the Layers for both sections should be made ofthe same materials, be placed in the same order of arrangement and havethe same thicknesses. However, for the calculations, the smallestthickness of the air chambers present in these Envelope-Roof-Sectionswill be taken into account (likely the one of the non-slopped roof). Fora sloped Envelope-Roof-Sections the thicknesses to consider for thecalculations are the ones taken at the zone where they are shortest,having a tolerance of 30 cm from the edge of the section for the unions(as long as the continuity of the Layers is kept).

The Envelope-Layers have a thickness, a thermal conductivity, a vaporpermeability and an order of arrangement, all of which will matter forthe Calculation Methods here disclosed. The order of arrangement,considered from the outermost Layer to innermost Layer or vice-versa,may vary as long as the K-Max Condition and the No-CondensationCondition are satisfied, but, for the sake of the calculations, itshould be kept constant across all the Envelope-Sections of the sameType, for all the Modules of a given building. The Envelope-Layers maybe of the following Types:

-   -   (a) Structural Insulated Panels (SIPs), typically comprising an        insulating foam core sandwiched between two structural facings        such as OSB, plywood, sheet metal, gypsum sheathing, and many        other varieties. In the preferred embodiments, SIPs with        polyurethane cores and sheet metal or gypsum sheathing are used        because of their excellent performance.    -   (b) Boards of any kind, including gypsum-based boards for walls        and ceilings, OSB and plywood, boards, for example for        Floor-Sections, and other kinds of boards for support or        sheathing (for example Alucobond for some finishes, and hardwood        or ceramic tiles for flooring, etc.).    -   (c) Supporting-Frames, which may include the corresponding        Envelope-Section's Aeriated Frame and, in some embodiments other        Frames which share the main characteristics (a, b and c) of the        Aeriated Frames as defined in this specification, but whose main        function may be unrelated to structural support. Instead, they        may be added between two Layers to create air chambers or to        expand the thickness of existing air chambers.    -   (d) Sheets. Such as paint films, fabrics, radiant barriers,        firestop wraps, vapor barrier sheets, protective coatings and        other kinds of thin Layers, whose thicknesses are negligible for        calculation purposes, but whose thermal conductivity and        or/vapor permeability make their consideration relevant for the        calculation.    -   (e) Insulating-Layers, such as glass wool, Fiberglass, blown-in        insulation, foams, etc., whose function may be primarily for        thermal insulation or for sound insulation.    -   (f) Additional-Intervening-Layers: Different embodiments of        Envelope-Sections may include combinations of the        above-mentioned kinds of Layers, with their possible variations        and repetitions, and they may also include other kinds of        materials and combinations not listed here. Still, whenever a        material is included as a Layer (in the broad sense hereabove        described) within an Envelope-Section, and this material has a        non-negligible thermal conductivity and or/vapor permeability,        it must be considered as an Envelope-Layer and included in the        calculations for the K-Max and the No-Condensation Conditions.

Note: Non-intervening Elements may also be added: Different embodimentsof Envelope-Sections may further include Non-intervening elements suchas non-continuous layers, Non-aeriated Frames, cables, tubes, andstructural elements which do not create air cambers and whose thermalconductivity and vapor permeability are negligible for the K-Max andNo-Condensation Conditions' calculation purposes. Their inclusion nothaving an impact in the calculation, they are considered as“Non-intervening” and may be added for a variety of functions (includingmere ornamentation), not needing to be considered for the calculations.

Back to FIGS. 5 and 6, they schematically exemplify not only a possibleconfiguration of Envelope-Layers, but also the thermal behavior of therespective Envelope-Sections they illustrate. For FIG. 5, going from theinnermost Layer to the outermost Layer (left to right in the figure),the first Layer is a gypsum board 32, then a glass wood Layer 33, apolyethylene vapor barrier sheet 34 applied to a SIP (for example agypsum-polyurethane Sandwich Panel) 35, an air chamber 36 (actuallycreated by a Supporting-Frame which would be at the same time theWall-Frame of the Support Structure) and, finally, a second SIP 37, thatcould be, for example, a metal sheet-polyurethane Sandwich Panel.

Reference number 38 shows the interior temperature as being 18° C.,while the exterior temperature is shown with reference number 39, asbeing −3° C. The curve 40 shows the evolution of the temperature fromLayer to Layer of the Envelope-Section. The curve 41 shows the evolutionof the dew point temperature Layer to Layer throughout theEnvelope-Section. The vertical segment 42 represents the effect that thevapor barrier sheet has in this dew point temperature curve. The factthat, in this figure, the curve 41 is lower at all points than the curve40 and never touches or crosses it, is a graphical representation of theNo-Condensation Condition. (If this example, the Condition would besatisfied, meaning that the risks of superficial and interstitial watercondensation in the studied Envelope-Section are minimal). The sameconcept is replicated in FIG. 6, in which 38 shows the interiortemperature, 39 the exterior temperature, 40 the temperature curve and41 the dew point temperature curve. The horizontal segment 42 representsthe effect that the vapor barrier sheet has in this dew pointtemperature curve, where, as the curve 41 is lower (in this case, moreto the right) at all points than the curve 40 and never touches orcrosses it, the No-Condensation Condition would also be theoreticallysatisfied in this example. The Layers in FIG. 6 are, from outermost toinnermost: A SIP 37, a truss' sloped beam 43 (that acts as aSupporting-Frame) creating an air chamber 46, a glass wood Layer 33, astructural beam 44 (part of an equally thick Supporting-Frame) and vaporbarrier sheet 34 applied to a gypsum suspended celling 45 and defining asecond air chamber 47. The thicknesses of the air chambers are measuredas follows: air chamber 46 is measured at a line separated at most 30 cmfrom the beginning edge of the Envelope-Section and air chamber 47 ismeasured from the gypsum board's 45 upper face (in which the vaporbarrier 34 is applied) to the Envelope-Roof-Frame 44's Outer Face.

FIG. 7 shows a possible embodiment of a union between anEnvelope-Wall-Section 48 and an Envelope-Floor-Section 49. The columns44 a and beams 44 b that are part of the Support-Structure of theillustrated Module, give support to the mentioned Envelope-Sectionsforming air chambers, 36 for the wall and 51 for the floor. TheEnvelope-Layers for the Envelope-Wall-Section 48 of this particularembodiment include an exterior sheathing Layer 50 (for example,Alucobond), and a metal sheet-polyurethane Sandwich Panel 37 for theOuter-Wall-Section, and a gypsum-polyurethane Sandwich Panel 35, a glasswool insulating Layer 33 and a gypsum board 32 for theInner-Wall-Section. Reference number 34 marks where the vapor barriersheet would be in this example. The Envelope-Layers for theEnvelope-Floor-Section 49 includes, from bottom to top, a first OSBboard 52 a, coupled to the Floor-Frame of the Support Structure , then aSupporting-Frame 53 made, in this case, from a plurality of parallel “C”profiles coupled to said board, a second OSB board 52 b coupled on topof the Supporting-Frame 53, a metal sheet-polyurethane Sandwich Panel 37over it, then a third OSB board 52 c and lastly a hardwood floor 54.Spaced perforations may be added to the C-Profiles, the structural beams44 b, or both, to ensure the unobstructed air flow within the airchamber 51. These Layers may be replaced—in other embodiments—by otherLayers, with different materials, functions, quantities and order ofarrangement, as long as the Conditions disclosed in this specificationare still satisfied.

FIG. 7 also shows a foundation and a possible way in which the Modulesmay be secured to said foundation. This is only an example and may bemodified in other embodiments to an immense variety of options thatserve the same purpose. In this example, the first step consists on thesite's preparation by digging a 50 cm deep hole in the terrain of thesize and shape of the projected home and removing at least 30 additionalcentimeters of soil per side, outside of the building perimeter.Subsequently, selected soil 58 is evenly poured over the bottom of thehole (approximately 20 cm deep), and the forms 57 are laid throughoutthe perimeter of where the Modules will be placed. Forms 57 should betight, rigid and strong (for example, made from scrap lumber). Steelreinforcing bars 56 are then positioned as required by the size andcharacteristics of the project, and the first stage of concrete 59 (tothe inside of the forms 57) is poured. An arrangement of L-Shaped anchorbolts 60 is then added, before the concrete dries out, having a size andseparation matching the size and separation of a series of holespreviously made for this purpose on the Floor-Frames of the Modules tobe installed. Once the concrete is dry, the Modules are put in theirplace with all the anchor bolts going through the respective holes andadjusted with nuts. Finally, a second stage of concrete 61 is poured tothe outside of the forms 57 to complete the foundation. The soil aroundthe foundation (55) is then finished to match it to the level of theterrain.

FIG. 8 shows a possible embodiment of a union between anEnvelope-Wall-Section 48 and an Envelope-Roof-Section 62. The columns 44a and beams 44 b that are part of the Support-Structure of theillustrated Module, give support to the mentioned Envelope-Sectionsforming air chambers 36 for the wall and 46 for the roof. TheEnvelope-Layers for the Envelope-Wall-Section of this particularembodiment include an exterior sheathing Layer 50 (for example,Alucobond), and a metal sheet-polyurethane Sandwich Panel 37 for theOuter-Wall-Section 48 a, and a gypsum-polyurethane Sandwich Panel 35, aglass wool insulating Layer 33 and a gypsum board 32 for theInner-Wall-Section 48 b. Reference number 34 marks where the vaporbarrier sheet of the wall would be in this example. The Envelope-Layersfor the Envelope-Roof-Section 62 include, from top to bottom, a metalsheet-polyurethane Sandwich Panel 37 supported over a sloped truss 43,and a suspended ceiling system 45 comprising a gypsum board which hasapplied to it a vapor barrier sheet 34. These Layers may be replaced—inother embodiments—by other Layers, with different materials, functions,quantities and order of arrangement, if the Conditions disclosed in thisspecification are still satisfied.

FIG. 9 shows a possible embodiment of the union between an internal SIPwall 35 and a Floor-Section including a SIP 37, an OSB board 52 and ahardwood floor 54. The union is made through a “U” shaped profile 63.FIG. 10 shows a possible embodiment of the union between an internal SIPwall 35 and a structural beam 44 b. The union is made through the use oftwo “L” shaped profiles 64. FIG. 11 shows a possible embodiment of theunion between two internal SIP walls 35. The union is made through an“L” shaped profile 64 and two “U” shaped profiles 63.

FIG. 12 shows an embodiment of a Module having an Envelope-Wall-Section48, an Envelope-Roof-Section 62, a Non-envelope-Wall Section 65 and aNon-envelope-Floor section 66. A possible reason for a layout as the onehere shown is that the Module is purposed to be a second floor of atwo-story house, and to have another Module adjacent to it through theNon-envelope-Wall section 65. The Support-Structure of this illustrativeModule is made of columns 44 a, beams 44 b, sloped truss members 43 andsome other additional framing members 44 to support the truss. The maindifference between the Envelope-Wall-Section 48 and theNon-envelope-Wall Section 65 is that the first one includes an airchamber 36, and several Envelope-Layers, while the second one onlyincludes, in this example, a gypsum board 32 and is not subject to theconditions set out by the Calculation Methods. The Envelope-Layers forthe Envelope-Wall-Section 48 of this particular embodiment include ametal sheet-polyurethane Sandwich Panel 37 for the Outer-Wall-Section,and a gypsum-polyurethane Sandwich Panel 35 and a gypsum board 32 forthe Inner-Wall-Section. The Envelope-Layers for theEnvelope-Roof-Section 62 includes, from top to bottom, a metalsheet-polyurethane Sandwich Panel 37 supported over a sloped truss 43, aglass wool insulating Layer 33 and a suspended ceiling 45 (which is madeof a gypsum board), forming an air chamber 47. These Layers may bereplaced—in other embodiments—by other Layers, with different materials,functions, quantities and order of arrangement, if the Conditionsdisclosed in this specification are still satisfied. As the spaces 69are filled by air, the same concept explained in FIG. 6 would apply forthe measurement of the thickness of the other air chamber contained inthis roof section, for the application of the Calculation Methods. Theroof-wall corner union is sealed by an angled profile 68. TheNon-envelope-Floor section 66 includes an OSB board 52 and a hardwoodfloor 54.

FIG. 13 shows an embodiment of the longitudinal union between twoEnvelope-Wall-Sections each pertaining to one of two adjacent Modules,20 and 21. The columns 44 a and beams 44 b that are part of theSupport-Structure of the illustrated Modules, give support to thementioned Envelope-Wall-Sections. The Envelope-Layers for theEnvelope-Wall-Sections of this particular embodiment include an exteriorsheathing Layer 50 (for example, Alucobond), and a metalsheet-polyurethane Sandwich Panel 37 for the Outer-Wall-Section, and agypsum-polyurethane Sandwich Panel 35, a glass wool insulating Layer 33and a gypsum board 32 for the Inner-Wall-Section, forming an air chamber36. To join the Modules, a column 44 a of one of the Modules is situatedside by side to a column of the other Module and coupled together withthe use of two flat metal bars 68. A plurality of Layers 70 isafterwards completed with their corresponding materials at theconstruction's site, once the Modules are fixed in their definitivepositions.

FIGS. 14 and 15 show an embodiment of the perpendicular union betweentwo Envelope-Wall-Sections each pertaining to one of two adjacentModules, 20 and 21. FIG. 14 is a general view in which the outer wallsection 48 a and the inner wall section 48 b are simplified for a bettervisualization of the relative positions of the Modules involved. Thebeams 44 b and columns 44 a of both Modules are shown. The dashed lines71 show where the relevant beams and columns of the Modules would bepositioned once they are joined together. FIG. 15 shows in more detailthe Envelope-Layers of one of the unions between these two illustrativeModules and how they are joined together. The Envelope-Layers for theEnvelope-Wall-Section of this particular embodiment include an exteriorsheathing Layer 50 (for example, Alucobond), and a metalsheet-polyurethane Sandwich panel 37 for the Outer-Wall-Section, and agypsum-polyurethane Sandwich Panel 35, a glass wool insulating Layer 33and a gypsum board 32 for the Inner-Wall-Section, forming an air chamber36. Beams 44 b are shown. To join the Modules, a column 44 a of one ofthe Modules is situated side by side to a column of the other Module andcoupled together. A plurality of Layers 70 is afterwards completed withtheir corresponding materials at the construction's site, once theModules are fixed in their definitive positions. The dotted line 72marks the limit between the two original Modules, for further clarity.

FIG. 16 shows an embodiment of a prefabricated modular panel for anEnvelope-Outer-Wall-Section, conceived for its application as a part ofa prefabricated modular panel system. This panel may be designed to beadapted for its installation to any Aeriated Support Structure. A panelaccording to this invention should contain the Envelope-Layersestablished by the methods here described and should couple to theSupport Structure and to its adjacent panels to cover the totality ofthe Envelope-Section it belongs to. Similarly to this panel, otherpanels may be used to cover the inner wall section, roof section andfloor section of the house or building being constructed. Thisillustrative panel includes framing members 44, a SIP 37, a gypsum board32 and a glass wool insulating Layer 33. To join a panel to the nextone, perforated square section parts 73, screws and nuts may be used.

Calculation Methods

FIGS. 17-29 relate to the Calculation Methods for the relevantparameters of the Envelope-Layers. These methods include the “K-MaxMethod” to find a configuration of Layers that satisfies the “K-MaxCondition”, the “No-Condensation Method” to find a configuration ofLayers that satisfies the “No-Condensation Condition” and the“Optimization Method” to optimize these parameters for a minimumK-Value, a minimum total cost or other objectives set by the User. Themethods are to be applied by a “User”, understanding by “User” anyindividual or organization interested in constructing a Zero-Energy homeor building as per this specification, any part thereof, and/or inproviding any product or service related to the claimed invention. TheK-Max and the No-Condensation Conditions, as herein defined, arerequisites for the configuration of the Envelope-Layers in anyZero-Energy home or building in accordance with the present invention.However, the specific methods here disclosed for their calculation aremerely illustrative and a wide array of variations to these methods maybe applied, that would still give as a result values serving the samegeneral purpose, variations which are included in spirit and scope ofthe invention as defined by the appended claims. Other embodiments ofthese methods include manual operations and corresponding computersystems, apparatus, and computer programs recorded on one or morecomputer storage devices, each configured to perform the actions of themethods. For every table and sub-table presented, other measurementunits different than the herein disclosed may be used with thecorresponding conversions and adjustments.

FIG. 17 shows the main tables used in one possible embodiment of theCalculation Methods. These tables may represent excel worksheets, csvfiles, text files, MySQL tables or any kind of database capable ofstoring the provided information in a suitable way for its processing asdisclosed. Even if the use of computers for these methods is preferred,some or all of the tables may also be generated through the manualregistration of the information and some or all of the methods may bemanually applied. The tables used may have, in other embodiments,different, fewer, or additional fields, rows and columns, and may bearranged in other ways (use fewer tables, for example, if some of thetables here disclosed are joined together in one). The disclosedarrangement of tables—to be used in Excel with the possibility ofapplying Microsoft's Excel Solver for the Optimization Method—ispreferred.

Reference number 80 designates Table 1, which is further disclosed inFIGS. 18a and 18b . Table 1 stores the values of the constants needed toapply the disclosed methods. These constants are provided by thisspecification but may be altered for other embodiments in the ways thatwill be disclosed later in this specification. Reference number 90designates Table 2, which is further disclosed in FIG. 19. Table 2stores the values of the variables, related to each specific project,entered by the user for the application of the disclosed methods. Morevariables than the ones here disclosed may be added to otherembodiments, as well as variations of the variables here disclosed thatwill still serve the same general purpose. Reference number 100designates Table 3, which is further disclosed in FIG. 21. Table 3stores the values of the relevant parameters of the different materialsand components of the Envelope-Layers needed for the application of thedisclosed methods. These values may be obtained from up-to-datecommercial catalogs available to the User, and they may vary for eachdifferent project. Additional parameters to the ones here disclosed maybe recorded in other embodiments, as well as variations of theparameters here disclosed that will still serve the same generalpurpose. Reference number 110 designates Table 4, which is furtherdisclosed in FIG. 23. Table 4 is the main Table for the application ofthe Calculation Methods, putting together relevant information from theother tables, and storing some of the results of the calculationsperformed by these methods. The layout of this table, as well as therows and columns included in it, may be modified in other embodiments aslong as the variations still serve the same general purpose. Referencenumber 120 a designates Table 5, which is further disclosed in FIG. 27.Table 5 stores the values of the parameters that will be used for theOptimization Process 120 b. These parameters, which include theobjective values to be optimized and the constraints to apply in theOptimization Method, are based on the other tables and, if the othertables are modified in other embodiments, these parameters may vary too.The Optimization Method is separated from the K-Max and theNo-Condensation Methods and all said methods may be used independentlyfrom one another. The dotted arrows in FIGS. 17-28 represent theexchange of information to between tables and processes. The dottedarrows in FIG. 17 generally represent the flow of information betweenTables 1-5 and the Optimization Process 120 b. The following tables andflowcharts will specify in more detail the nature of these interactions.

FIGS. 18a and 18b show a possible layout for an embodiment of Table 1(80), which is the table used for storing the constants used by theCalculation Methods. Table 1, in this embodiment, is separated in threeSub-tables: Sub-table 1 (81) which stores the maximum values of theK-values allowable by the K-Max Method depending on the temperature ofthe projected location of the building, Sub-table 2 (82), which storesthe information related to the superficial resistances of eachEnvelope-Section, and Sub-table 3 (83), which stores the informationrelated to the air chambers.

In FIG. 18a , Sub-table 1 (81) has the following columns:

Column 81 a, “Exterior temperature” measured in ° C. This temperaturemay also be measured in ° F. or any other unit for temperature, with thecorresponding conversions and adjustments. In this column, the minimumand maximum annual temperatures for the location of the Building will besearched. The location can be as specific as the city, town, or zip-codeor latitude-longitude coordinates of the place where a specific buildingwill be located, or as general as a bio-climatic zone or a wholecountry. In any case, the maximum and minimum annual temperatures forthe geographic area considered are applied.

Column 81 b, “KMAX(WS)”, is the Maximum K-Value allowable for theEnvelope-Wall-Section; Column 81 c, “KMAX(RS)”, is the Maximum K-Valueallowable for the Envelope-Roof-Section; and Column 81 d, “KMAX(FS)”, isthe Maximum K-Value allowable for the Envelope-Floor-Section of the homeor building, all measured in W/m2 K. This demanding standard, of theinventor's own development, reflects a reasonable goal to achieveaffordable Zero-Energy buildings with the use of the materials, designsand calculations herein disclosed. As will be shown later, the maximumK-value desirable for a given project may be defined by the User as anyvalue lower to the maximum allowable values disclosed by this table.However, no values higher to them should be permissible, except for atolerance of at most 20% of the disclosed maximum allowable values,since more than that would negatively impact the energy-efficiency ofthe Building Envelope to an unacceptable degree. Alternatives toK-values and equivalents to the proposed measurement units may beapplied with the corresponding conversions and adjustments. These valuesof K-Max (81 b, 81 c and 81 d) correspond to each value of exteriortemperature (81 a) of the table.

In FIG. 18b , Sub-table 2 (82) has the following columns:

Column 82 a, “Layer-Type”, has two Layer-Types, ESR (that stands for“Exterior Superficial Resistance”, as stated in column 82 b, “Concept”),and ISR (that stands for “Interior Superficial Resistance”, as alsostated in column 82 b). These represent, respectively, the values to beused for the integration of the concepts of exterior and interiorsuperficial resistances of each of the Envelope-Sections to be takeninto account for the calculations. For this embodiment, the ESR and theISR are treated as the first and last Envelope-Layers of each section,applying for them the values contained in this table. The only actualvalues that this table contains are the ones corresponding to Column 82e, “R”, in which the thermal resistance of each of these “Layers”,measured in m2k/w is stated. The other columns are filled with “n/a”meaning that for these “Layers” these concepts are not to be applied.These concepts are added as a way of normalizing the information becausethey are used in the other Layers:

Column 82 c, “Th”, is the thickness of the Layer (measured in m)

Column 82 d, “λ”, is the thermal conductivity of the Layer (measured inW/mk)

Column 82 f, “δ”, is the vapor permeability of the Layer (measured ing/m h kpa)

Column 82 g, is the surface area of the Envelope-Section, measured in m2

Column 82 h, “Option”, indicated by an integer number, is a numberrepresenting which of the options for this particular Layer, of the onesthat can be found in Table 3 (100) is the one to be applied for thisLayer.

As previously stated, for the two “Layer-Types” object of thissub-table, values for columns 82 c-h are non-applicable nor needed forthe calculations. Other embodiments include other ways of integratingthe consideration of the interior and exterior superficial resistancesinto the calculations. Other parameters, variables and units may be usedto this end, with their corresponding conversions and adjustments.

Sub-table 3 (83) has the following columns:

Column 83 a, “Option”, indicated by an integer number, is a numberdesignating which one of the options for the current Layer thecorresponding row will define. Each option will be defined by a numeralstarting with “1”. For this embodiment, 7 different options for each ofthe air chambers are suggested, but these numbers may vary in otherembodiments, as long as the air chambers are properly considered in thecalculations.

Column 83 b, “Envelope-Section”, represents to which of theEnvelope-Sections the air chamber in consideration pertains(Envelope-Wall-Section, Envelope-Roof-Section orEnvelope-Floor-Section).

Column 83 c, “Layer-Type”, is a letter of the alphabet representing thetype of Layer the row designates. In this sub-table, the only two Typesof Layers used are “G” (for the Envelope-Wall-Section air chambers) and“H” (for the Envelope-Roof-Section and Envelope-Floor-Section airchambers).

Column 83 d, “Concept”, simply states the concept of these Layers (allof them are “air chambers”) It is easy to see how some of these columnsare only for illustrative purposes of a particular embodiment and may beomitted or modified in other embodiments. The letters for identifying agiven Envelope-Layer, for example, are merely conventional and any otherconvention may as well be used.

Column 83 e, “Th”, is the thickness of the Layer (measured in m)

For this embodiment the thickness ranges to be considered are:

1—0.005 m to 0.009 m

2—0.010 m to 0.019 m

3—0.020 m to 0.049 m

4—0.050 m to 0.099 m

5—0.100 m to 0.149 m

6—0.15 m to 0.199 m

7—0.200 m to 2 m

These thicknesses were chosen for consideration because of the relevantvalues they provide for the Calculation Methods. However, otherthicknesses, other ranges, and other measurement units may be used withthe corresponding conversions and adjustments.

Column 83 f, “R”, is the thermal resistance of the Layer (measured inm2k/w)

Column 83 g, “λ”, is the thermal conductivity of the Layer (measured inW/mk)

Column 83 h, “δ”, is the vapor permeability of the Layer (measured ing/m h kpa)

The values of columns 83 f-h for air chambers are well known in thefield of the invention, and any equivalent thereof may be used as longas the inclusion of the air chambers and their impact in the thermal andcondensation performance of the Building Envelope are properlyconsidered in the Calculation Methods.

In FIG. 19, Table 2 (90) has the following columns:

Column 90 a, “Concept”, states in few words the main idea what eachvariable represents, while Column 90 b, “Variable” states thealphanumerical code used to identify each of the variables.

Column 90 c, “Value”, is the value that the User assigns for eachvariable, which may be re-entered for each different project. Thesevalues are expressed in the units of measurement stated in Column 90 d,“Unit”.

The variables to be defined by the User may vary from embodiment toembodiment, as also the way of executing these inputs may vary too. Thevalues may be typed directly in the corresponding cells, as in the caseof an excel file, or they may be entered through an online or offlineform, dialogue box, imported from a file, etc. The variables used in theshown embodiment are:

Max Temperature (Tmax), is the maximum annual temperature at theprojected location of the building.

Min Temperature (Tmin), is the minimum annual temperature at theprojected location of the building.

Interior Relative Humidity (IRH) is the ideal relative humidity expectedto have inside of the building for health and comfort.

Exterior Relative Humidity (ERH) is highest annual exterior relativehumidity at the projected location of the building.

Wall Section's Surface Area, S(WS), are the total square meters ofsurface that the whole Envelope-Wall-Section of the building isprojected to have (counted only once, and valid for all theIntervening-Layers).

Roof Section's Surface Area, S(RS), are the total square meters ofsurface that the whole Envelope-Roof-Section of the building isprojected to have (counted only once, and valid for all theIntervening-Layers).

Floor Section's Surface Area, S(FS), are the total square meters ofsurface that the whole Envelope-Floor-Section of the building isprojected to have (counted only once, and valid for all theIntervening-Layers).

Interior Temperature Goal, (ITG), is the ideal interior temperatureexpected to have inside of the building for health and comfort.

Max K desirable for Wall Section, Kmax (WS), is the maximum K-value thatthe user is willing to accept for the Envelope-Wall-Section This may beentered manually based on any Standards that the User is interested incomplying with.

Max K desirable for Roof Section, Kmax (RS), is the maximum K-value thatthe user is willing to accept for the Envelope-Roof-Section This may beentered manually based on any Standards that the User is interested incomplying with.

Max K desirable for Floor Section, Kmax (FS), is the maximum K-valuethat the user is willing to accept for the Envelope-Floor-Section Thismay be entered manually based on any Standards that the User isinterested in complying with.

The values for these variables shown in the table are only examples ofvalues that could reasonably be entered by the User in a possibleembodiment, for illustrative purposes.

FIG. 20 illustrates a possible process in which the values of thevariables of Table 2 (90) could be entered by the user. Tmax, Tmin, ERH,IRH, S(WS), S(FS), S(RS) and ITG are entered in step 91, for example bytyping the values directly in the corresponding cells, as in the case ofan excel file, or entering them through an online or offline form,dialogue box, importing them from a file, etc. The same possibilities,and other conceivable alternatives, are applicable for every input inthese methods. Kmax (WS), Kmax (RS), and Kmax (FS) are entered in step92. These values are the maximum desirable K-values as defined by theUser, and they are to be compared to the maximum allowable values forthe K-values of each of the Envelope-Sections obtained from Table 1 (80)for both winter and summer conditions. Step 93 retrieves from Table 1the K-values corresponding both to the Tmax and the Tmin just entered instep 91. This may be achieved, in the case of an excel file, through theapplication of the VLOOKUP function for said entered temperatures inTable 1, providing as a result the corresponding maximum allowableK-values for the wall, roof and floor sections.

These K-values are compared in step 94 to the corresponding maximumdesirable K-values previously entered by the user in step 92. If all thedesirable values entered in step 92 are less than or equal to themaximum values allowed by Table 1 (80) and obtained in step 93, then thevalues are accepted and the values of all the variables entered in steps91 and 92 are submitted as outputs to Table 2 (90), in step 95. However,if at least one of the values entered in step 92 is not permissible forbeing greater than its corresponding maximum allowable K-value from step93, new maximum desirable K-values need to be entered and the processshould restart from step 92.

In FIG. 21, Table 3 (100) consists of several Sub-tables (100 a-h), onefor each Layer-Type (A to H). These Layer-Types are, for thisembodiment: Gypsum Boards (A), Insulating Layers (B), Vapor Barriers(C), SIPs (D), OSB Boards (E) Wood Floors (F), Wall Air Chambers (G) andFloor or Roof Air Chambers (H). For other embodiments the Layer-Typesmay vary and so may the information to be recollected for each of them.Each Sub-table has the following columns:

“Option”, indicated by an integer number, is a number designating whichone of the options for the current Layer-Type the corresponding row willdefine. Each option will be defined by a numeral starting with “1” andthe number of options for each Layer-Type will vary in function of thenumber of options that the user has availability of and wants toconsider for the methods.

“Th”, is the thickness of the Layer for the corresponding option(measured in m)

“λ”, is the thermal conductivity of the Layer for the correspondingoption (measured in W/mk)

“δ”, is the vapor permeability of the Layer for the corresponding option(measured in g/m h kpa)

“$”, is the price in dollars (per square meter) for the correspondingoption.

These values may be obtained from commercial catalogs, general technicalinformation about the materials, official standards, online resourcesetc. Any equivalents or variations of the parameters considered for eachLayer-Type may be used as long as their inclusion does not alter thegeneral results of the Calculation Methods.

In a simple version of the Calculation Methods, one single variety foreach Layer-Type may be considered. In that case, only the thicknessneeds to be modified for the Calculation Methods, the other variablesremaining constant for all options, and associated to the physicalproperties of the material(s) in question. This simplified scenarioallows the elimination of the integer constraints of FIG. 28's step 129.Instead, the constraints used here should be the maximum and minimumthicknesses allowed for each layer, and the variable cells for thissimplified case may be the thickness cells instead of the option cells.In cases like this, linear programming such as the Simplex Algorithm andsoftware such as Lindo may be used for the Optimization Method. Someembodiments may include a mixture of simplified options where only thethickness is variable with options where the other variables acquiredifferent values as well. Other more complex embodiments, on the otherhand, may involve additional variables such as densities, qualities,commercial brands, varieties, etc.

FIG. 22 illustrates a possible process in which the values of thevariables of Table 3 (100) could be entered by the User. For each optionof each Layer-Type, Th, λ, δ and $ are entered in step 101, for exampleby typing the values directly in the corresponding cells, as in the caseof an excel file, or entering them through an online or offline form,dialogue box, importing them from a catalog or file, etc. The thermalresistance of each option of each Layer-Type, “R”, (measured in m2k/w),is then calculated using F1 in step 102. F1 is the first of the formulasincluded in FIG. 29, suggested for their use in these CalculationMethods, although other formulas or approximation methods may be usedfor obtaining equivalent results.

R=Th/λ  F1:

This simply means that R for an option is obtained by dividing thethickness for that option by the thermal conductivity for that sameoption. In the case R is provided in the catalogs, of course, it doesnot need to be calculated, and the thermal conductivity may need to becalculated instead in some cases. The values of all the variablesentered in steps 101 and 102 are submitted as outputs to Table 3 (100),in step 103. The same process is done for every option of everyLayer-Type until reaching Layer-Type Gin step 104. Layer-Type G is anair chamber. The information of air chambers is stored in Sub-table 3(83) of Table 1 (80). This information for air chambers G and H isretrieved from said sub-table in step 105. Step 106 adds the cost ofcreating an air chamber of for the thickness of each option. This pieceof information should be added considering the materials such asadditional beams and columns that will be needed to create an airchamber of those characteristics. All the information relating toprices, like this one, will only be needed for the methods involving theminimization of costs, while other methods like the K-Max Method or theNo-Condensation Method may eventually ignore them. The values of all thevariables entered in the applicable iterations of steps 105 and 106 aresubmitted as outputs to Table 3, in step 107.

In FIG. 23, Table 4 (110) has the following columns:

Column 110 a, “Layer-Type”, is a letter, or letters representing thetype of Layer the row designates together with a description of theconcept for each Layer-Type. The Layer-Types should be presented foreach Envelope-Section 111 a in the actual order of arrangement theEnvelope-Layers would have in the building, from innermost to outermostand including the ISR and the ESR for each Envelope-Section.

Column 110 b, “Layer Number” indicated by an integer number, is a numberdesignating which one of the Layers for the current Envelope-Section thecorresponding row will define, indicating also the order of arrangementof the Layers of each Envelope-Section from innermost to outermost.

Column 110 c, “Th”, is the thickness of the Layer (measured in m)

Column 110 d, “λ”, is the thermal conductivity of the Layer (measured inW/mk)

Column 110 e, “R”, is the thermal resistance of the Layer (measured inm2k/w)

Column 110 f, “K”, is the K-value of the Layer (measured in W/m2 K)

Column 110 g, “t”, is the temperature of the interior surface of theLayer (measured in ° C.)

Column 110 h, “δ”, is the vapor permeability of the Layer (measured ing/m h kpa)

Column 110 i, “Pv” is the vapor pressure of the Layer (measured in kpa)

Column 110 j, “Td” is the dew point temperature at the interior surfaceof the Layer (measured in ° C.)

Column 110 k, “Δt” is the difference between the temperature of and thedew point temperature at the interior surface of the Layer (t minus Td)

Column 110 l, “$” is the price in dollars (per square meter) for thecorresponding option of the current Layer.

Column 110 m, “KMC” is a binary variable acquiring the value of “1” whenthe “K-max Condition” is satisfied for the Layer and the value of “0”when it is not satisfied.

Column 110 n, “NCC” is a binary variable acquiring the value of “1” whenthe “No-Condensation Condition” is satisfied for the Layer and the valueof “0” when it is not satisfied.

Column 110 o, “Option”, indicated by an integer number, is a numberdesignating which one of the options available for the currentLayer-Type in Table 3 (100) applies for the current Layer. The desiredoption may be entered manually by the user or automatically tried by theoptimizer process or other automation processes. The information in thistable should be tied to the information on Table 3 in such a way that ifthis option is changed (for example selected from a drop-down menu) thevalues of the corresponding columns for that row are updated to reflectthe contents of Table 3 for the selected option (for example, throughthe use of the VLOOKUP function in excel).

The cell 111 b is the total K-value of the Building Envelope, calculatedas the sum of all the K-values in column 110 f. This is the cell thatwill be minimized if the Min-K-Value version of the Optimization Method.

The cell 111 d is the total cost of the Building Envelope, calculated asthe sum of all the prices in column 1101. This is the cell that will beminimized if the Min-Cost version of the Optimization Method.

The content of several cells in the table of this example (some pointedwith 111 c) refer to formulas (F2, F5, F6, etc.) which are the formulasof FIG. 29 suggested to be used for the calculation of the values ofthese variables in function of the values of the other variables that,as the table indicates, are obtained from the other tables. For example,“f/Table 1” means that the value for that cell is obtained from Table 1(80). 111 e are binary variables acquiring the value of “1” when the“No-Condensation Condition” or when the “K-max Condition” (depending onthe column) are satisfied for all the Layers of an Envelope-Section andthe value of “0” when said Condition is not satisfied for at least oneof them. All of these values should be “1” for the K-max Condition andthe No-Condensation Condition of the home or building to be satisfied.

In this embodiment, the Layer Types of column 110 a for each EnvelopeSection, including their order of arrangement, are manually selected bythe User. However, in other embodiments, this selection may be automatedand included in the Optimization Method, subject to certain restrictionsto be defined by the User. In this case, the Optimization Method wouldnot only select the options of the Layers (in a fixed order ofarrangement defined by the User) that satisfy all the constraints andoptimize the selected goal, but it would further define the optimalLayer Types, quantity of each, and order of arrangement that satisfy allthe constraints and optimize the selected goal, subject to therestrictions defined by the User. This would throw as a result an evenmore effective configuration of the Envelope Layers due to theconsideration of a significantly larger set of alternatives.

FIG. 24 explains in more detail how the values for Table 4 (110) areobtained. The values for columns 110 c, 110 d, 110 e, 110 h, 1001 and110 o for the ISR and ESR Layers of each Envelope-Section are retrievedfrom Table 1 (80) in step 112 a. Then, for the other Layers of eachEnvelope-Section, the values for the same columns are retrieved fromTable 3 (100) in step 112 b, with the exception of “R” (column 110 e)which is calculated using F1 in step 113, and the values of all thevariables entered in the previous steps are submitted as outputs toTable 4, in step 114. After completing these values for all the Layersof all the Envelope-Sections, the total values of R for eachEnvelope-Sections are calculated in step 115 by using the F2 formula ofFIG. 29:

X _(section)=Σ_(l=1) ^(n) X  F2:

This means that all the values of a variable (in this case “R”) for allthe Layers of an Envelope-Layer are added up to calculate the totals ofthat variable for the Envelope-Layer. These values are stored in thethree bottom rows (Marked as “Totals”) of the corresponding column ofTable 4 (110) in FIG. 23. In step 116 of FIG. 24, the values for thethree bottom rows (Marked as “Totals”) of Column 110 f of FIG. 23(corresponding to the total K-values of each Envelope-Section) areobtained by calculating the inverse of the total values of R justobtained in step 115 (1/Total R, for each Envelope-Section). The totalvalues of δ, for each Envelope-Sections are then calculated in step 117,also by using the F2 formula of FIG. 29, this time applied to δ (column110 h of FIG. 23). These values are submitted as outputs to Table 4 instep 118. The rest of the cells of Table 4 in FIG. 23 will be calculatedwhen applying the No-Condensation Method, explained in FIG. 25 and theK-Max Method, explained in FIG. 26.

No-Condensation Method

The No-Condensation Method has as its main goal the verification of theabsence of any substantial risks of Interstitial and/or Superficialcondensation of water in a Building Envelope comprising Envelope-Layersas defined by this specification. For doing this, the both thetemperature (t) and the dew point temperature (Td) of the interiorsurface of each Layer for each Envelope-Section are calculated andcompared in such a way that the “Δt” (the difference between thetemperature and the dew point temperature, t minus Td) for every Layeris positive, meaning that there are no significant risks of superficialor interstitial condensation. FIG. 25 shows an embodiment of a method inwhich the No-Condensation Condition may be verified. However, otherembodiments may include substantial variations in the way of performingsuch verification. For example, a psychrometric diagram may be usedinstead of the proposed equations. In FIG. 25, the binary variable “NCC”has an initial value of “0” in step 130 a, meaning that theNo-Condensation Condition is still not verified.

The values of ITG, Tmax, Tmin, S(WS), S(RS), S(FS), IRH and ERH areretrieved from Table 2 (90) in step 131, and the values of R(WS), R(RS),R(FS), δ(WS), δ(RS), δ(FS), and δ(1) for every Envelope-Section areretrieved from Table 4 (110) in step 132, where δ(1) is just the valueof δ for the first Layer of each Envelope-Section. ASVP is thecalculated in step 133 by using the F3 formula from FIG. 29:

$\begin{matrix}{{\Delta \; {SVP}} = {\frac{\left( {6.11 \cdot \frac{\exp \left( \frac{\left( {17.27 \cdot {ITG}} \right)}{\left( {237.3 + {ITG}} \right)} \right)}{10}} \right){IRH}}{100} - \frac{\left( {6.11 \cdot \frac{\exp \left( \frac{\left( {{17.27 \cdot T}\; \min} \right)}{\left( {237.3 + {T\; \min}} \right)} \right)}{10}} \right){ERH}}{100}}} & {F3}\end{matrix}$

In this formula, SVP stands for Saturated Vapor Pressure and ASVP is thedifference between the Interior SVP (first term of the F3 formula) andthe Exterior SVP (second term of the F3 formula). The IRH and ERH usedfor this calculation are retrieved from Table 2 (90).

Then, for every Layer of every Envelope-Section, Pv (0) of theEnvelope-Section is calculated in step 134 by using the F4 formula fromFIG. 29:

$\begin{matrix}{{PV}_{0} = {\frac{\left( {6.11 \cdot \frac{\exp \left( \frac{\left( {17.27 \cdot {ITG}} \right)}{\left( {237.3 + {ITG}} \right)} \right)}{10}} \right){IRH}}{100} - {\Delta \; {{SVP} \cdot \frac{\delta_{1}}{\delta_{section}}}}}} & {F4}\end{matrix}$

Pv (0) is the initial vapor pressure for each Envelope-Section which maybe obtained by subtracting ΔSVP times the vapor permeability of theFirst Layer of the Envelope-Layer divided by the total vaporpermeability of the Envelope-Section, to the Interior Saturated VaporPressure. Subsequently, the R, δ and $ of each Layer (corresponding tothe manually or automatically selected option for the Layer) areretrieved from Table 4 (110) in step 135. The Layer's temperature isthen calculated in step 136 using the F5 formula from FIG. 29:

$\begin{matrix}{T_{n} = \left\{ {{{{{ITG} - \frac{R_{n}\left( {T_{{ma}\; x} - T_{m\; i\; n}} \right)}{R_{section}}}:n} = 1},{{T_{n - 1} - \frac{R_{n}\left( {{T\; \max} - {T\; \min}} \right)}{R_{section}}}:{n > 1}}} \right\}} & {F5}\end{matrix}$

This formula is bifurcated in two different situations: When n=1 (thatis, for the first Layer of each Envelope-Section) the temperature isobtained by calculating a “temperature variation term” consisting of theR (for that Layer) times the difference between Tmax and Tmin, bothobtained from Table 2 (90), divided by the total R of the correspondingEnvelope-Section, and subtracting this “temperature variation term” fromthe ITG. However, when n>1, that is, for all the other Layers of eachEnvelope-Section, not being the first one, the temperature is calculatedby subtracting said “temperature variation term” to the temperature ofthe previous Layer.

In the next step (step 137) the vapor pressure for each Layer iscalculated by using the F6 formula from FIG. 29:

$\begin{matrix}{{PV}_{n} = {{PV}_{n - 1} - {\Delta \; {{SPV} \cdot \frac{\delta_{n}}{\delta_{section}}}}}} & {F\; 6}\end{matrix}$

In this formula, the ΔSVP times the vapor permeability of the Layerdivided by the total vapor permeability of the correspondingEnvelope-Section is subtracted from the vapor pressure of the previousLayer to obtain the vapor pressure of the current Layer. It is importantto remember that the vapor pressure for the first Layer of theEnvelope-Section had already been calculated in step 134. In step 138the dew point temperature of the Layer is calculated, using the F7formula of FIG. 29:

$\begin{matrix}{{{Td} = {{C\; {1 \cdot \left( {{{Pv} \cdot 10} - 3} \right)}C\; 2} + {C\; 3\; {\ln \left( {{{Pv} \cdot 10} - 3} \right)}} + {C\; 4}}}{{{{where}:\begin{pmatrix}{C\; 1} \\{C\; 2} \\{C\; 3} \\{C\; 4}\end{pmatrix}} = {\begin{pmatrix}82.45 \\0.12 \\3.06 \\196.81\end{pmatrix}:{{0.16\mspace{14mu} P\; a} < {Pv} < {610.74\mspace{14mu} P\; a}}}},{{{and}\begin{pmatrix}{C\; 1} \\{C\; 2} \\{C\; 3} \\{C\; 4}\end{pmatrix}} = {\begin{pmatrix}33.38 \\0.22 \\7.16 \\246.76\end{pmatrix}:{{610.74\mspace{14mu} P\; a} < {P\; v} < {101340\mspace{14mu} P\; a}}}}}} & {F\; 7}\end{matrix}$

F7 uses four variables, C1, C2, C3 and C4, which can take differentvalues depending of the range of Vapor Pressure applying to the case.This formula is well known in the art and any equivalent thereof or anygood approximation method may also be used for the calculation of thedew point temperature at each Layer. As previously stated, this can aswell be observed in a psychrometric diagram. The Layer's Δt is finallycalculated in step 139 by using the F8 formula of FIG. 29, that is,simply subtracting the td of the Layer from the t of the Layer.

ΔT=t−td  F8:

If this difference is greater than zero, that means, if the temperatureof the Layer is greater than the dew point temperature at the Layer, aschecked in step 140, it means that there are no significant risks ofcondensation for that particular Layer. If this is the case, all therelevant variables for that Layer are submitted as output to Table 4(110), in step 141 and the process is repeated, from step 135, for everyLayer of the Envelope-Section.

If Δt for a Layer is 0 or less than 0, this means that there areunacceptable risks of water condensation in that Layer and therefore thecurrent selection of options for that Envelope-Section is notacceptable. If this happens, step 119 b refers to a connector “A” whichat its time refers to the connector “A” 119 a of FIG. 24. This meansthat in the case that the No-Condensation Condition is not satisfied foran Envelope-Section, the whole process of FIG. 24 for thatEnvelope-Section needs to be repeated starting from step 119 a, andselecting a different option, having a higher vapor permeability, forthe Layer that caused the problem, and/or making other modifications,either manually or automatically, tending to solve the identifiedproblem. Once this is done, the process of FIG. 25 should be repeated,until finding a solution that satisfies the Condition Δt>0 for all theLayers of the Envelope-Section. Once this happens, the total cost of theEnvelope-Section is calculated in step 142 by using the F9 formula ofFIG. 29 and the results submitted as outputs to Table 4 in step 143.

Section's Total Cost=Σ_(l=1) ^(n)$_(l) ·S _(section)  F9:

According to this formula, the total cost on the Envelope-Section may becalculated by adding all the individual costs by square meter of eachLayer and multiplying them by the corresponding square meters of surfaceof the section. Obviously, prices may be available by unit or by othermeasures and other methods for the calculation of the total cost of theEnvelope-Section may also be used.

The process is repeated from step 134 for the remainingEnvelope-Sections, until the Condition Δt>0 is satisfied for all theLayers of all the Envelope-Sections.

When this happens the No-Condensation Condition for the building issatisfied. NCC acquires the value of “1” in step 130 b to reflect it,the final cost of the Envelope-Section is calculated by adding up thetotal costs of each of the Envelope-Sections in step 144, and all therelevant variables, including the total Envelope cost and theinformation that NCC is met, are submitted as outputs to Table 4 in step145. To the total cost of the Building Envelope calculated in step 144,other costs of the building may be added, including the cost of labor,the cost of the solar energy generator and any other costs associated tothe construction and set up of the Zero-Energy home or building. Thus, amore complete information would be available for decision making and,when using the optimization method, the total cost may be minimizedinstead of the cost of just the Building Envelope. The Zero-Energy goalmay be reached through different combinations of Building Envelopeoptions and renewable energy generation systems, If the OptimizationMethod takes into account these alternatives it may help the User findthe most overall cost-efficient way of achieving this goal.

K-Max Method

The K-Max Method has as its main goal the verification that the totalK-value of every Envelope-Section of a building is less than or equal tothe maximum K-Value allowed for that Envelope-Section. FIG. 26 shows anembodiment of a method in which the K-Max Condition may be verified.However, other embodiments may include substantial variations in the wayof performing such verification. In FIG. 26, the binary variable “KMC”has an initial value of “0” in step 150 a, meaning that the K-MaxCondition is still not verified. In step 151, the Kmax for eachEnvelope-Section is retrieved from Table 2 (90). It is important torecall that these K-values cannot be higher than the Kmax valuescorresponding to Tmin or to Tmax in Table 1 (80) (except for theadmitted 20% tolerance). The calculated K-values for eachEnvelope-Section are retrieved in step 152 from the totals for eachEnvelope Section of Column 110 f of Table 4 (110) in FIG. 23. Step 153compares these values. The calculated K-values from step 152 should beless than or equal to the Kmax values from step 151, for allEnvelope-Sections. If they are not, that means if the calculated K-valueof an Envelope-Section is greater than the maximum permissible K-valuefor that section, step 119 b refers to a connector “A” which at its timerefers to the connector “A” 119 a of FIG. 24. This means that in thecase that the K-Max Condition is not satisfied for an Envelope-Section,the whole process of FIG. 24 for that Envelope-Section needs to berepeated starting from step 119 a, and selecting a different options,having a higher R, for one or more of the Layers of the Envelope-Sectionthat caused the problem, and/or making other modifications, eithermanually or automatically, tending to solve the identified problem. Oncethis is done, the process of FIG. 26 should be repeated, until finding asolution that satisfies the Condition 153 for all Envelope-Sections.

When this happens the K-Max Condition for the building is satisfied, KMCacquires the value of “1” in step 150 b to reflect it, and theinformation that KMC is satisfied is submitted as output to Table 4(110) in step 155.

Optimization Method

The Optimization Method has as its main goal finding those options forthe Envelope-Layers of a Zero-Energy home or building as per thisspecification that satisfy both the K-Max Condition and theNo-Condensation Condition and, at the same time, minimize the total costof the Envelope, the total overall cost of the building, the totalK-value of the Building Envelope or any other relevant variables thatthe User wishes to minimize or maximize while maintaining bothConditions satisfied.

FIG. 27 shows a table (Table 5, 120 a) and FIG. 28 shows a process(Optimization Process 120 b) for a possible embodiment of the method inwhich the optimization may be performed. This embodiment uses ExcelSolver to achieve this goal. However, other embodiments may includesubstantial variations in the way of performing such optimization, forexample through the use of custom programing, other optimizationsoftware or even manual procedures of linear or non-linear programmingand operations research.

In FIG. 27, Table 5 (120 a) has the following columns:

Column 110 a, “Layer-Type”, is a letter, or letters representing theType of Layer the row designates together with a description of theconcept for each Layer-Type. The values of 110 a for this table are thesame values of 110 a for Table 4 (110) of FIG. 23.

Column 110 b, “Layer Number” indicated by an integer number, is a numberdesignating which one of the Layers for the current Envelope-Section thecorresponding row will define, indicating also the order of arrangementof the Layers of each Envelope-Section from innermost to outermost. Thevalues of 110 b for this table are the same values of 110 b for Table 4(110) of FIG. 23.

Column 121 a, “Layer's Constraint”, indicated by an integer number, is anumber indicating how many options are there on Table 3 (100) for thecorresponding Layer-Type.

Column 121 b, “Solver variable”, is a binary variable acquiring thevalue of “1” when the number of options stated in Column 121 a isgreater than 1 (that is, if there are at least two options for theLayer) and the value of “0” when the Layer does not have any options tochoose from (and, therefore, the value of 121 a is “1”)

The values for these variables shown in the table are only examples ofvalues that could reasonably be entered by the User in a possibleembodiment, for illustrative purposes.

In FIG. 28, the binary variable “Optimized” has an initial value of “0”in step 122 a, meaning that the optimization has not yet been achieved.For every Layer of every Envelope-Section, the Layer number andLayer-Type are retrieved from Table 4 (110) in step 123, and the numberof options for the Layer-Type is retrieved form Table 3 (100) in step124. In step 125, a variable “N” acquires the value of the quantity ofoptions just obtained in step 124, and this value will represent theLayer's Constraint that will be stored in the corresponding row ofColumn 121 a of Table 5 (120 a) of FIG. 27. The subprocess 126 assignsthe value of “1” to the Solver Variable of column 121 b of Table 5 whenN>1 (when there are at least two options for that Layer) and the valueof “0” when there are no options to choose from. In step 127, all therelevant variables submitted as output to Table 5. The same process isrepeated for every Layer of every Envelope-Section. Once it's done, theobjective to minimize should be selected. Step 128 a selects to minimizethe final cost of the Envelope-Section, which corresponds to cell 111 dof Table 4 in FIG. 23, while Step 128 b selects to minimize the finalK-value of the Envelope-Section, which corresponds to cell 111 b ofTable 4 in FIG. 23. Step 129 then specifies all the parameters to beused to set up Excel Solver to optimize the results. Other solversoftware may use the same, similar, or different parameters for theirsetup. In this case, Solver is applied to Table 4, which at the sametime is “tied” to all the other tables being updated every time thecorresponding information in the other tables is updated and vice-versa.The objective cell to enter at the dialog box of the Solver is the cellselected in step 128, a orb (111 d or 111 b, respectively). “Min” ischosen because the selected cell should be minimized. In the field “Bychanging the variable cells” all the cells of the column 110 o of Table4 for those rows in which the value of the solver variable of column 121b of Table 5 is “1” shall be selected. This means that the variablesthat the solver needs to modify are those which have different optionsto choose from, in Table 3. The constraints are then set up, so that allthe values of the 111 e cells of Table 4 are “1” (which means that boththe K-Max Condition and the No-Condensation Condition are satisfied forthat solution), an “integer” constraint is added for every one of thevariable cells, and another constraint is added for every one of thevariable cells defining a maximum value of N for it, where N is thenumber of options available for that Layer-Type in Table 3, number whichmay be obtained from column 121 a of Table 5 in FIG. 27. Finally, the“Make unconstrained variables non-Negative checkbox is checked and the“Evolutionary” solving method is selected.

With these parameters, Solver is applied in step 120 b. If Solver findsa feasible solution in step 120 c, then the “Optimized” variableacquires the value of “1” in step 122 b to reflect it, and theinformation that the optimization has been achieved, together with allthe relevant variables, are submitted as outputs to Table 4 (110) instep 120 d.

If Solver does not find a feasible solution in step 120 c, then step 100b refers to a connector “B” which at its time refers to the connector“B” 100 a of FIG. 22. This means that in the case that there are nooptimal solutions, the No-Condensation Condition, the K-Max Condition,or both are not satisfied by any possible combination of Layer options.If this happens, the design of the Envelope (the quantity and order ofarrangement of the Layers) should be modified, more or better optionsfor some or all of the Layer-Types should be added to Table 3 (100),and/or any other modifications tending to solve the identified problemshould be applied, after which the whole processes of FIGS. 22, 24, 25and 26 need to be repeated starting from step 100 a in FIG. 22. Oncethis is done, the process of FIG. 28 should be repeated, until Solverfinds a feasible solution.

The description as set forth is not intended to be exhaustive or tolimit the invention to the precise form disclosed. Many modificationsand variations are possible in light of the teachings above withoutdeparting from the spirit and scope of the forthcoming claims.

What is claimed and desired to be secured by patent is as follows:
 1. Amethod for calculation of acceptable parameters of Intervening-Layers ofan energy-efficient Building Envelope for a Zero-Energy buildingcomprising: a) a database containing constants and a first set ofvariables to be used by the method, said constants including maximumK-values allowed for an Envelope-Wall-Section, an Envelope-Roof-Sectionand an Envelope-Floor-Section in function of exterior temperature at aprojected location of the Zero-Energy building; b) input by a User ofvalues of a second set of variables to be used in the method, includingbio-climatic conditions at the projected location of the Zero-Energybuilding, a projected surface area of the Envelope-Wall-Section, theEnvelope-Roof-Section and the Envelope-Floor-Section, and a plurality ofoptions for at least one Envelope Layer of at least one Envelope Sectionincluding information about thickness, vapor permeability and heattransfer properties of each option of each Envelope Layer; c)verification of a “No-Condensation” Condition by comparing a temperatureto a dew point temperature at each Envelope Layer of each EnvelopeSection; and d) verification of a “K-Max” Condition by comparing theK-value of each Envelope Section to the maximum K-values entered in stepa.
 2. The method of claim 1 further comprising automatic selection ofthe options for each Envelope Layer of each Envelope Section thatminimize total K-value of the Building Envelope through the use ofoptimization software.
 3. The method of claim 1 further comprising: a)input by a User of prices of each option of each Envelope Layer; and b)automatic selection of the options for each Envelope Layer of eachEnvelope Section that minimize the total cost of the Building Envelopethrough the use of optimization software.
 4. The method of claim 2wherein the thicknesses, thermal conductivities, and vaporpermeabilities of at least two options of at least one of theEnvelope-Layers are considered for the determination of the combinationsof Envelope-Layer options that minimize the total K-value of theBuilding Envelope.
 5. The method of claim 3 wherein the thicknesses,thermal conductivities, vapor permeabilities and prices of at least twocommercially available options of at least one of the Envelope-Layersare considered for the determination of the combinations ofEnvelope-Layer options that minimize the total cost of the BuildingEnvelope.